Roots Industries Report

INTRODUCTION

Roots Industries India Limited was the first to start American Auto Service (1970). Roots India Limited is head quartered at Coimbatore, South India. The first company to introduce servo brakes for light motor vehicles. Roots have been a dominant player in the manufacture of horns and other products like Castings and Industrial Cleaning Machines. The company, promoted by Mr.K.Ramasamy, Chairman & Managing Director diversified to manufacture high frequency wind. With a strong innovative base and commitment to quality, Roots Industries India Limited has occupied a key position in both international and domestic market as suppliers to Original Equipment Markets and after market. The turnover of Roots Industries India Limited is about 70 crores per annum. There are 1000 employees working in the industry. Roots is a leading Original Equipment supplier to major vehicle manufacturers like Mercedes Benz, Mitsubishi, Mahindra, Toyota, TELCO, Rover, Pal Peugeot, etc. This has strengthened the Research & Development activities and increased Roots technical competence to international standards. On the joint venture woes the company has tied up with the British company to produce inflatable jacks. Roots Industries has also entered in a technical collaboration with Robert Bosch s.a. This move helps them to increase production capacity to 3 million horns p.a. M/S J.Osawa & co, Japan, one of the largest industrial groups of that country. Roots are the only Indian company that meets the demanding standards of the Japanese markets. Roots cleaning equipment and die cast parts, etc. are exported to USA, Europe, Australia, Japan, South America, Far East and several other advanced countries.

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COMPANY PROFILE Roots Industries Private Limited was established in 1970, with a vision and commitment to produce and deliver quality product adhering to international standards. Roots Industries is the 11th largest Horn Manufacturing Company in the world. And also the first Indian Company to get ISG/TS 16949 Certification based on effective implementation of QS 9000. Roots Industries single minded of enhancing the quality of life has led to many other diversifications. ROOTS today is a multifaceted corporate entity with interests in automobile accessories, cleaning equipments, castings, precision tools, high technical engineering services, healthcare and education. Roots Vision: The company’s vision statement is follows: “We will stand technologically ahead of others to deliver world-class innovative products useful to our customers. We will rather lose our business than our customer’s satisfaction. It is our aim that the customer should get the best value for his money. Every member of our company will have decent living standards. We care deeply for our families, for our environment and our society. We promise to pay back in full measure to the society by way of selfless service and unstinted service.” Environmental Policy: With due concern towards maintaining and improving the quality of life, Roots is committed for sustainable development by minimizing pollution and conserving resources. This will be achieved through continual improvement in Environmental awareness of all employees and associates legal compliance and objective towards environmental protection.

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Quality Policy: Roots Industries is committed to provide world class products and since with due concern for the environment and safely to the society.  Continuous improvement in quality  Technology up-gradation  Cost reduction  Total employee involvement quality will reflect in everything the company does and think  Quality in behavior  Quality in human relation  Quality in governance

ROOTS GROUP OF COMPANIES

Roots Industries India Pvt Ltd a conducted study on performance management system. Since the inception the company has spun off several divisions that scattered to a wide range of services. Roots Industries India Private Limited (RIL): Roots Industries India Ltd was the first shoot of American Auto Services. Since then there has been no looking back in terms of growth and diversification. RIL’s versatile product range includes a comprehensive array of automobile horn, auto lamps, pistons and sophisticates parking guide system. The company currently enjoys 60% market share in automobile horn market. Its growing leadership stands has been enough incentive for RIS to start operations in Malaysia as well.

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Roots Auto Products Private Limited (RAPPL): RAPPL has grown from a small manufacture of horns to India’s large air horn manufacturing company, in just a span of 5 years. Today, RAPPL enjoys a market share of about 70% in the air horn segment. The company’s product offering do not just stop with a wide variety of air horns. They also include a host of auto accessories like flashers, horn relays, dual head lamp relays, melody makers, lever switches etc., that are renewed for their stringent quality standards. Roots Cast Private Limited (RCPL): Established in 1985, RCPL set out to manufacture a wide variety of Aluminium and Zinc pressure die-cast components for various industrial and domestic purposes. These components vary from 8 grams to 1250 grams and this has thrown open the field for ample opportunity to cast a host of products. The company also specializes in manufacturing critical and exclusive components for the automobile, textile and healthcare industries. Roots Poly Craft (RPC): RPC manufactures precision plastic components. Specialized parts like trumpets and connectors are examples of the team’s dedication to quality and productivity. It also produces parts requiring insert

moulding ultrasonic welding and vacuum-impregnation, meeting stringent quality

standards.

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ORGANISATION CHART CHAIRMAN & MANAGING DIRECTOR MR. K. RAMASAMY

FINANCE MRS. R.K. UMAADHEVI DIRECTOR

MR. K. RAVI

HUMAN RESOURCES

SALES & MARKETING

CHIEF FINANCIAL OFFICER

DR. KAVIDASAN

MR. S. CHANDRASEKAR

& COMPANY SECRETARY

DIRECTOR

EXECUTIVE DIRECTOR

PRODUCTION

PURCHASE

MR. K. SARAVANASUNDARAM

MR. K. GUHAN

CHIEF EXECUTIVE OFFICER

DIRECTOR

& DIRECTOR

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FUNCTION IN THE ORGANISATION The following are the important divisions in Roots Industries India Private Limited:  PRODUCTION DEPARTMENT  FINANCE DEPARTMENT  HUMAN RESOURCES DEPARTMENT  SALES DEPARTMENT  MARKETING DEPARTMENT  PURCHASE DEPARTMENT

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PRODUCTION DEPARTMENT

In Roots Industries India Pvt Ltd, they are producing 1500 horns per day at a maximum of 500000 horns per year. The press shop has four hydraulic machines for manufacturing. The production process differs from one unit to the other. There are different sections for each part manufacture of horn.

Coil Winding Zone: Coil Winding: Type: Smart one coil Method: machine-programmed Required: spool and coil Diameter of the coil: 0.515 mm Speed: 75% Turns: 256 Procedure: The spool is kept in place and the machine is started or pushed button for the coil to automatically wound around the spool. This happens with the rotation of the spool. Routing: Method: manual Purpose: The coil in the spool is routed to bring up the friction. Procedure: The ends of the coil are fitted to the spool tightly.

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Hot Sealing: Purpose: The coil to be fixed tightly. Procedure: the routed coil is fixed in the machine and certain air pressure and temperature melts the coil in place. Types: 1. Smart One coil Air pressure: 2v Temperature: 220`C 2. FD-4 coil Air pressure: 4v Temperature: 300`C 3. W-75 coil Air pressure: 6v Temperature: 300`C Cleaning: Purpose: The enamel feed to have magnetic flux which helps in connections. Defects: 1. Loose winding 2. Uneven 3. Coil thickness Procedure: The defects are checked and the defective coils are disposed.

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Riveting: 1. Cold air riveting: Method: machine Type: rolling Air pressure: 2.5v Time: 2.0 sec Procedure: The pointer of the machine rolls on the point of the plate of the condenser holder. 2. Axel air riveting: Method: manual Procedure: The lever of the machine is pulled down due to which the machine pointer punches the point of the strider plate. 3. Hot riveting: Method: machine Procedure: The pointer of the machine creates a spark of fire on touching the point melting it, fixing the point to the point plate.

Assembly: Trumpet diaphragm assembly is the HEART OF THE HORN. Purpose: Used for sound amplification. It absorbs SER which becomes magnetic. Type: Conduct & non-conduct PROCEDURE: 1. Spool holder riveting: 

The diameter and diode stepping are assembled correctly in the spool.



The conduct of the coil is checked.



The spool holder is riveted in place. 9

2. Terminal riveting & Tuning screw insertion/Base: 

It is a thermal base riveting.



The spool contains a nail which is already attached is fixed to the nail.

3. Diode continuity/ Clamping voltage checking: 

The product is checked towards the positivity and negativity.

4. Diaphragm assembly riveting & Height measuring: 

The height of the diaphragm is checked with a pointer and an indicator.



If the distance or the height is of correct measure, the rolling ground moves the diaphragm to rivet.



If the height is changed it moves it out of the line.

5. Gasket assembly/ Pre Grimping & Final grimping: 

Paper gasket fills the gap between the diaphragm assembly and grimping.



The distance is measured to be .45 mm thickness.



Pre grimping is done to have more air space.



The air gap is found between the armature rod & spool center rod.

6. Air gap measuring & adjusting: 

The air gap is measured with a machine which gives green signal for correct measure and red signal for incorrect measure.

7. Pre tuning & mounting bracket assembly: 

According to the customers preference the tuning positions are already set, declared and the bracket is fixed.

8. Horn tuning and testing: There are 3 types of horns in respect with the voltage. They are 

12v



9v



14.5v

Blue light signals for low one & red light for high tone and green light for the feed up correct tone measure. An applied voltage of 4v &2.67v is given for testing the tone. 10

The correct measure of 750 db does not create any trouble. 9. Painting: 

Once the horns are tuned to be right then they are painted black.

Inspection: The inspector checks two or three random pieces from the pile of boxes in the barrier audit area/ material storage area. Dimension is checked. If one has any problem then the whole consignment will be segregated and checked.

Press Shop: Horn’s Critical Parts: 

Housing with SCR (Spool Center Rod) Assy.



Diaphragm (heart of Horn).



Tone Disc ---> produces sound.



Point light ---> used as conductor.



Point holder ---> used as conductor.

Materials: 

Aluminium Zinc Galvanizing steel



Cold rolled carbon steel



Stainless steel



Spring steel

High level Quality: 

Flexible



Good appearance



Changeability



Rust free

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Aluminium Nickel/export quality Rust free material and used for 3 to 5 years. Types Four: 

Power Press Minimum: 4 tone Maximum: 110 tone



Dymatic Feeder It is a semi automatic machine It feeds on all types of components Maximum: 200 tones Minimum: 50 tones 45 parts per minute Manpower: 1 It is much safer. If the worker’s hand exceeds the limit the machine stops automatically.



Hydraulic Press It takes time. Diaphragm thickness is more



Auto Feeding It is a regular continuous process

FIVE S: 

Sorting



Place for everything and everything in its place



Keeping clean



Standardization



Self discipline and training

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Quality Measures: 

First in & first out: The first material or order that enters press shop is duly finished first.



KAIZEN (change Better): For betterment of products, a change with innovation is processed and should be accepted from time to time.



POKA YOKE (Beware in all aspects): The workers are taught to put their keen concentration while handling machines.



PPM (Parts Per Million): It should be noted that the output should result in low defective parts.



Rejection and changes should be nil.

Measures: 

Delivery performance should be good in an overall aspect



Overall equipment effectiveness



Five S utilization



Internal customer satisfaction



Safety (less accidents and PPM usage)

Vision for 2010-2011: 

KAIZEN improvements



MTTR to be reduced



Improving machine utilization



Inventory control should be maintained



Add facilities in tool maintenance to improve the efficiency



Zero accidents



PPM is targeted



Five S implementation

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Vision for 2011 to 2012: 

Visual factory



Manpower reduction by introducing automatic machine



Self inspection introducing in minimum number of process to achieve the quality goal through TEZ



SAP utilization in machine loading plan, tool history card & data entry



Improving machine utilization

Powder Coating: Procedure: De-rusting  Oil will be there on surface for lubricants  Oil is removed in the conveyor belt with water for two and a half hours De-greasing:  Components are dipped in alkaline Zinc phosphating:  pH- 7.5  Alkaline is removed Passivation:  Sodium Nitrate  Phosperous pre-heated Powder Coating:  Sodium Chloride- 5% 14

 Power mixed with electrolyte to form charge

E-Core/ SER cleaning:  At 220`C the powder melts. Problems:  Repetitive bad parts  Machine and tool breakdown  Storage of material  Fallen parts

Electroplating: Electroplating is done to remove grease and rust. Procedure:  Soak cleaning-1: 

Chemical: Prelik-160



Temperature: 70`C



Purpose: removes oil

 Maladic cleaning: 

Chemical: Prelik-160



Purpose: gives reversing current

 Anodic cleaning: 

Purpose: removes grease.

 Water cleansing: 

3 Stages of water cleansing

 HCL- Prickling: 15



Ratio: 1:1



Purpose: to remove rust



Observation: Froth is formed on contact with oxygen

 Water Cleansing: 

3 Stages of water cleansing

 Caustic Dip: 

Chemical: Sodium Hydroxide-40%



Purpose: removes acidic/ to neutraline

 Zinc plating 

Chemical: Zinc 8-12 gram/liter



Sodium Hydroxide 120-140 gram/liter



Ion forms balls of zinc that dissolves



A dummy is kept as positive diode



The zinc rods are negative that absorbs zinc

 Water Cleansing: 

3 stages of water cleansing



Ph: 13>12>10

 Nitric dip: 

Chemical: Nitric acid 10ml/liter



Purpose: to remove alkaline

Chromating is done in acidic form  Water rinsing: 

3 stages of water cleansing



Different water ph for all three components

 Trivalent Yellow: 

Chemical: Chromium 150ml/liter

 Water cleansing: 

3 stages of water cleansing 16

 Hexavalent Yellow: 

Chemical: Chromium 8ml/liter

 Water Cleansing: 

3 stages of water cleansing

 Hexavalent Green: 

Chemical: Chromium 80ml/liter

 Water cleansing: 

3 stages of water cleansing

 Sealant: 

To seal the coat, a lamination coat of sealant is given for all the coloring components



Temperature: 50`C to 55`C

Defects: When one component touches the other there will be left some marks in the components. Inspection: The components are checked and the defects are visually seen and discarded.

CAST: Input:  Raw Material: Aluminium/Zinc Alloy (Ingots or Runners)  Consumables: Dynode (plunger dip/metal cleaning chemicals)  Men: trained operator, helper  Machine: HPDC machine, trimming press and furnace  Auxiliaries: rotary degasser, porosity tester &heating unit  Tool: Die casting die  Utilities: water, air, power, generator, compressor 17

Output:  Accepted castings for next process  Rejected parts send for melting  Generated runners and overflow pods return to stores  Dross and spoilage metal to scrap yard Working:  Furnace  it melts  Inject  it fills in die cavity  Die cavity  forms as to the prescribed shape Parts Produced: 

Fuel pump parts



Alternate parts



Starter motor parts



Engine parts



Auto-brake parts



Oil pump parts



Horn parts



Pneumatic parts



Compressor parts



Textile parts

Fettling: 

The extras are removed to make fine finishing



Usually manpower 18



If hard material then machine is used

POLYCRAFT: Preheat: ×

Materials with different grades are heated for 3 hours in preheating furnace

×

Temperature: 91`C. The preheat is done to dry the material

The plastic produced is used for the spool and diaphragm of the horn. Working: ×

The machine has a shape fixed in it or at least from a selection of different shape

×

The machine contains a furnace to melt the material.

×

Once the shape is fixed the machine gives out the horn plastic

×

Temperature: 80`C to 120`C

×

The machine is horizontal type

Exclusive Type: ×

Plastic tubes used in wires are produced

×

The rolling machine rolls the molten raw material in the form of a straw

Polypropylene: ×

A material used in vacuum cleaner

×

The machine is vertical type

Terminal Connector: ×

The component is made of nylon 19

×

It is used in horn

Insulator Bush: ×

It is used in horn

×

The machine is vertical type

FINANCE DEPARTMENT

The finance department functions efficiently in the concern. The records maintained in the company are cash book, petty cash book, Bills Receivable book, Bills Payable book, Pass book and other general books. Functions:  Overall responsibility of financial management  Preparation of cash flow statements  Preparation of budgets  Negotiation and liaison with banks and other financial institutions. Activities:  Maintaining funds  Payment to vendors in time  Budgeting  Statutory payments  Debtors collection  Working Capital Management The bankers of RIIL are:  Citi Bank  State Bank of India  Punjab National Bank 20

Companies fund: ¥ The companies fund consists of paid up capital, reserves and surplus, loans and advances, etc. ¥ Paid up capital consists of 16000 shares which are fully issued and subscribed. Maintaining funds: ¥ The company has a continuous monitoring mechanism available to keep track of collection period. ¥ The funds are maintained for the purchase of raw materials, components purchase, salary to staff, payment to creditors, payment of taxes, etc. Budgeting: ¥ Annual budget is made every year in the month of January or February every year. ¥ It is prepared by comparing the records of the previous year. ¥ The demand and various other factors are sorted according to the cost incurred and profit obtained. Statutory payments: ¥ The company also makes some statutory payments like central sales tax and sales tax for the purchase of raw materials and components. ¥ The company also gets TDS from the government. ¥ The company obtains the TDS Certificate. ¥ The form used for TDS is 16 A, which contains the details such as § Name and Address of the person to whom the tax is paid or received § Tax Deduction Account Number § Nature of payment made § Acknowledgement § TAN number § Period on Which TDS is paid 21

§ Details of payment

Payment to vendors: ¥ The company maintains a standard period of 60 days from the date of bill passed and 30 days in case of some special occasions. ¥ The company usually makes payment through cheque. ¥ The company also has a grace period of 5 days in case of default in payments. Debtors Collection: ¥ The debtors are allowed a period of 60 days from the date of passing of bill to make payments. ¥ The company also offers special cash discounts to the parties who make payments early. ¥ The customers who pay immediate payment are allowed 2.5% cash discount. ¥ If the party pays within 20 days he is allowed 2% cash discount. ¥ If the party fails in paying the debt he will be charged 18% over due on his bills.

Flow diagram for Vendors in Financial Distribution

Production Planning and Control

Purchase Order

Material Required

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Bill Passing

Payment

Flow diagram for Customers in Financial Distribution

Preparing Sales order

Delivery of Products

Creating Invoice

Receiving Payment

HUMAN RESOURCE DEPARTMENT

ROOTS have a strong people-oriented work culture that can be seen and felt across all its member concerns. Whether they work in group or in isolation, their effort is well appreciated and achievements well rewarded. There are about 1000 workers are employed in ROOTS. They have sense of belongingness and they stay in an environment of openness and trust. HR Objectives:  Customer satisfaction  Concern for the society  People for future, future for people HR Approaches:  Accept and Appreciate  Educate and Elevate  Balanced Leadership  Making employee a responsible citizen  Accept noble failures HR Practices: ¥ Focus: Every employee is taught not only to focus on their production but also their performance.

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¥ Change: Change is often advancement in production of units. The employees are trusted to accept the change. ¥ Performance: The employees are expected to give out their best performance. ¥ Motivation: The employees are motivated timely by performance appraisal. ¥ Work environment: A suitable and non-polluted environment is provided to the employees. Hr philosophy:  Openness and mutual trust among employees.  Team culture with no discrimination.  Customer first should be the oath of every employee.  Employee Empowerment is provided to increase the employees’ efficiency. Promotion: § Based on Organizational needs: If the company requires an experienced employee’s suggestion. § Based on Skill Requirements: The employee is promoted if he possesses excellent skills. § Based on Manpower: If there is requirement of more employees. Features: ф Suggestion schemes: Every employee is given a chance to suggest or comment on the company. ф Good morning assembly: Daily morning the employees are gathered and business news are read out. ф Monthly Motivational talk: A seminar is conducted monthly to motivate the employees. ф Thirukkural Mandram: Monthly a thirukkural is followed. ф Attendance award: Employees who work more than 90% of days are awarded. ф Performance reward scheme: Every half yearly the performance of the employees are noted and their respective rewards like promotion are given. ф Blood donation camps: To give knowledge about life blood camps are conducted. 24

Welfare Scheme:  Calculative for employees Children: Monthly amount is given for employee’s children’s education  Marriage Loan: Employees can apply for the loan which is deducted from the salary.  Super Annuation Scheme: 14% of the salary is provided as super annuation scheme.

Shifts: For Staff: 9 am to 5 pm For Workers: 

7.30 am to 4 pm



4 pm to midnight



Midnight to 7.30 am

RISE (Roots Institute Skill Exchange): RISE focuses on: 

Exchange: Students and employees are exchanged for both of the people’s improvement.



Growth: The Company should grow in such aspect.

Philosophy:  Share to Shine  Strength to Strength Institutions under RISE: ×

Avinashilingam University

×

Women’s Polytechnic

×

PSG

×

VLB 25

×

KCET

RISE Monitoring and Evaluation:  Panel Evaluation: The authorities are from both the university and the company to decide upon the exchange of people.  Steering Committee: They are consigned for periodical assessment.  Sub-Committee: The committee manages all the transactions between the company and the institution.

MARKETING DEPARTMENT

In ROOTS, marketing is done for the cleaning equipments. The Roots Multiclean Limited is responsible for marketing. Their various responsibilities:  Dispatching the finished good at the right time  Ensuring that the customer requirements are satisfied  Getting customers feedback  Planning the market activities for the future period  Handling new methods or techniques for marketing the products Sales Promotion Activities:  Participate in international Marketing Exhibitions  Direct domes in industries 26

 Advertising Products: ¥ Roots Hako flipper ¥ Roots hakomatic automatic scrubber drier Future Projects: ¥ Roots vegetable cutting machine ¥ Roots high pressure jet clean ¥ Roots Jet E-150 ROOTS handle THREE types of markets: ф Export Market For foreign countries. ф Original Equipment Market For Automobile companies. ф Replacement Market Local market sales and retail outlets. Highlights:  The only cleaning company in India to obtain ISO 9001-2000 Certification  Members of ISSA, USA  Member cleaning maintenance institute  Recipient of EEPC export award Competitors:  Minda  Padmini  Addon  Global and Solex horns 27

 Durga Electronics  Kobra Automotive horns  Satyam Automotive horns

SALES DEPARTMENT Sales are one of the activities of Roots Multiclean Ltd. It is a joint venture with Roots Industries Limited. It is technically and financially collaborated with HAKO works GMBH & Co., Japan. Sales Highlights: 

Largest network for sales and service in all the principal cities in India



Largest exporters



Three container loads of flipper and wizard exported to HAKO Australia for Olympic stadium cleaning in Sydney

Customers:  Ashok Leyland  Ford  TATA  Fiat  Volvo  Daimler Chrysler  Hindustan Motors  Caterpillar  TVS  Skoda  Mercedes Benz  Honda 28

Export to countries:  Germany  Australia  Italy  Japan  USA  Spain  Singapore  France  Brazil  UAE  Korea  United Kingdom  South Africa

PURCHASE DEPARTMENT The company also maintains a separate department for purchase which performs actions like purchasing of raw materials like steel, iron, plastic, fiber, coil wires, machines, etc. The materials are purchased based on the indent raised from the stores. Purchase Activities: § Vendor evaluation § Risk involved § Purchase order Functions: Φ The vendor is selected only when they satisfy various procedures like sample enquiries, sample approval, trial orders and quality reports.

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Φ Based on the quotations received a comparative chart is prepared and the lowest offer is selected and the orders are placed. Φ The payments are made through bank within 30-60 days. Φ While ordering the goods, 50% are made only against full delivery of goods. Φ The materials are returned to the vendor if the products fail to pass the quality testing. Φ The company also purchases from outside India.

CONCLUSION

Roots Industries India Limited has given me the opportunity in improving my practical knowledge and helped me to undergo a study on all the departments like human resource, marketing, sales, purchase, finance and production. The hospitality showed by the workers to me proved that the company has earned its name among its workers. I now have learnt the detail points of production process. I have also learned how human resource management is important in an organization. I understood the importance of proper financial management. The field training helped me to relate what we learnt in our class room to that of the organization. I had more practical exposure in the working atmosphere of ROOTS. The training which I got was very much useful in advancement of my career.

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